Harnessing green sand for superior steel castings
Today, more steel foundries are turning to automated green sand moulding to improve productivity, flexibility and casting consistency. Once considered mainly for iron production, green sand has proven its ability to support a wide range of steel casting applications while reducing labour requirements and lowering production costs. Depending on casting geometry, production volumes and foundry requirements, both horizontal and vertical moulding solutions can provide an efficient and reliable route to high-quality steel castings.
Advantages of using green sand for steel castings
- Efficient, flexible solutions from well under 100 right up to 555 moulds per hour
- Quick and easy pattern changes take less than two minutes, making them ideal for short runs
- Extensive automation requires only a minimal workforce
- Constant sand/metal ratio due to flaskless moulding
- Normally only one set of pattern plates is needed, even for high production volumes
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"It’s hard to make a breakthrough on your own."
DISA refined the fast, flexible green sand process during over 60 years of development. Now our new test foundry is accelerating its expansion into new steel, aluminum and copper alloy applications.
We spoke to Per Larsen, Innovation Manager at DISA, to get the inside story.
Steel Container Corners made on a DISAMATIC D5
Every year, over 4 million containers are produced, requiring more than 32 million new container corner castings.
Traditionally, these steel castings are made using shell moulding, which is slow, costly, old fashion, chemical-intensive and labor-intensive.
